Leveraging Simulators to Innovate Operator Training: City of Roseville, California SimuWorks Platform Development
Wednesday, September 30, 2026 11:00 AM to 11:30 AM · 30 min. (US/Central)
New Orleans Convention Center
Traditional Technical Session
Room 343
Information
Introduction
Process modeling is a well-established tool in wastewater treatment, commonly used to confirm design criteria, assess WRRF (Water Resource Recovery Facility) capacity, and optimize performance. However, its application has largely been restricted to engineering domains, with limited applications for operations professionals.
As part of an evaluation of their WRRF capacity, the City of Roseville, CA developed calibrated process models to represent the distinct process configurations of their two WRRFs. Each of the WRRFs utilizes a distinct process configuration. To extend the utility of these process models to operations, a SimuWorks operator training simulator was developed for each of the WRRFs.
SimuWorks is a dedicated operations tool which integrates the dynamic process model with a user interface which mirrors the real WRRF or its SCADA screens, providing a familiar environment for operators. This approach enables operations staff to engage with modelling tools for training, process control, and optimization without the steep learning curve associated with traditional process modeling software.
Methodological Approach
For each WRRF, a GPS-X process model was developed and calibrated using operational data. These calibrated models serve as the mathematical engine for the SimuWorks simulators. The simulator interface was designed to reflect the real-world overhead layout of each WRRF. The Dry Creek WWTP (Wastewater Treatment Plant) SimuWorks interface is shown in Figure 1.
The simulators incorporate both existing control system capabilities and additional controllers identified as potentially useful during the modeling process and from operator input. Each simulator can operate in open simulation mode, enabling WRRF operations professionals to test a wide range of process changes under varying flow and load conditions. This allows for both steady-state and dynamic analysis of the process in a risk-free environment, supporting process optimization, troubleshooting and operator training.
Results and Discussion
The SimuWorks simulator is designed to as an interactive training tool and includes five training exercises, summarized in Table 1. The training scenarios guide operators through operating strategies for challenging WRRF operating conditions identified by key stakeholders. These scenarios address critical treatment challenges and provide a safe environment for operators to practice control strategies without risk to public water sources. These scenarios also provide a way to exposure to extreme operating conditions which are challenging to navigate and too risky to replicate while operating the real WRRF. These scenarios provide an opportunity to test simulate these conditions, enhancing operator confidence and preparedness for handling these extreme events in real-world WRRF operation. An example training exercise is shown in Figure 2.
In addition to serving as a training platform, SimuWorks was designed to support day-to-day operational decision making. Operators are encouraged to create their own dynamic and steady-state simulations to evaluate alternative control strategies and assess their impact on key performance indicators (KPIs) and operating costs.
The Dry Creek WRRF SimuWorks simulator includes several advanced control features that allow operators to test and refine process control strategies. These include:
Ammonia Based Aeration Control (ABAC)
An interactive ABAC controller enables operators to define ammonia concentration ranges and the corresponding dissolved oxygen (DO) control setpoints for the aerobic zones of the aeration basin. The ABAC controller interface is shown in Figure 3.
Dewatering Controllers
A configurable dewatering/filtrate controller allows users to schedule intermittent pumping of sludge to dewatering processes or filtrate to the headworks. Operators can simulate different time-based pumping strategies during dynamic simulations to evaluate their effects on process performance and available storage. The sludge pumping controller interface is shown in Figure 4.
Status and Schedule for Ongoing Work
The SimuWorks simulator for the Dry Creek WWTP was delivered to the City of Roseville in September 2024. Since then, operations staff have actively used the tool to evaluate facility performance, test alternative control strategies and train operators.
Development of the SimuWorks simulator for the Pleasant Grove WWTP is currently underway, with final delivery anticipated in early 2026. Once complete, both simulators will be available to all City of Roseville operators for training, process optimization, and planning.
Conclusion
Traditional process simulators are often too complex for effective hands-on-operator training. By providing a user interface that mirrors the actual treatment process while only surfacing the critical control elements, SimuWorks enables operators to engage with process modeling in a familiar and intuitive environment. The addition of guided training exercises further enhances learning by allowing staff to safely explore challenging scenarios, ultimately improving process understanding and operational readiness.
Process modeling is a well-established tool in wastewater treatment, commonly used to confirm design criteria, assess WRRF (Water Resource Recovery Facility) capacity, and optimize performance. However, its application has largely been restricted to engineering domains, with limited applications for operations professionals.
As part of an evaluation of their WRRF capacity, the City of Roseville, CA developed calibrated process models to represent the distinct process configurations of their two WRRFs. Each of the WRRFs utilizes a distinct process configuration. To extend the utility of these process models to operations, a SimuWorks operator training simulator was developed for each of the WRRFs.
SimuWorks is a dedicated operations tool which integrates the dynamic process model with a user interface which mirrors the real WRRF or its SCADA screens, providing a familiar environment for operators. This approach enables operations staff to engage with modelling tools for training, process control, and optimization without the steep learning curve associated with traditional process modeling software.
Methodological Approach
For each WRRF, a GPS-X process model was developed and calibrated using operational data. These calibrated models serve as the mathematical engine for the SimuWorks simulators. The simulator interface was designed to reflect the real-world overhead layout of each WRRF. The Dry Creek WWTP (Wastewater Treatment Plant) SimuWorks interface is shown in Figure 1.
The simulators incorporate both existing control system capabilities and additional controllers identified as potentially useful during the modeling process and from operator input. Each simulator can operate in open simulation mode, enabling WRRF operations professionals to test a wide range of process changes under varying flow and load conditions. This allows for both steady-state and dynamic analysis of the process in a risk-free environment, supporting process optimization, troubleshooting and operator training.
Results and Discussion
The SimuWorks simulator is designed to as an interactive training tool and includes five training exercises, summarized in Table 1. The training scenarios guide operators through operating strategies for challenging WRRF operating conditions identified by key stakeholders. These scenarios address critical treatment challenges and provide a safe environment for operators to practice control strategies without risk to public water sources. These scenarios also provide a way to exposure to extreme operating conditions which are challenging to navigate and too risky to replicate while operating the real WRRF. These scenarios provide an opportunity to test simulate these conditions, enhancing operator confidence and preparedness for handling these extreme events in real-world WRRF operation. An example training exercise is shown in Figure 2.
In addition to serving as a training platform, SimuWorks was designed to support day-to-day operational decision making. Operators are encouraged to create their own dynamic and steady-state simulations to evaluate alternative control strategies and assess their impact on key performance indicators (KPIs) and operating costs.
The Dry Creek WRRF SimuWorks simulator includes several advanced control features that allow operators to test and refine process control strategies. These include:
Ammonia Based Aeration Control (ABAC)
An interactive ABAC controller enables operators to define ammonia concentration ranges and the corresponding dissolved oxygen (DO) control setpoints for the aerobic zones of the aeration basin. The ABAC controller interface is shown in Figure 3.
Dewatering Controllers
A configurable dewatering/filtrate controller allows users to schedule intermittent pumping of sludge to dewatering processes or filtrate to the headworks. Operators can simulate different time-based pumping strategies during dynamic simulations to evaluate their effects on process performance and available storage. The sludge pumping controller interface is shown in Figure 4.
Status and Schedule for Ongoing Work
The SimuWorks simulator for the Dry Creek WWTP was delivered to the City of Roseville in September 2024. Since then, operations staff have actively used the tool to evaluate facility performance, test alternative control strategies and train operators.
Development of the SimuWorks simulator for the Pleasant Grove WWTP is currently underway, with final delivery anticipated in early 2026. Once complete, both simulators will be available to all City of Roseville operators for training, process optimization, and planning.
Conclusion
Traditional process simulators are often too complex for effective hands-on-operator training. By providing a user interface that mirrors the actual treatment process while only surfacing the critical control elements, SimuWorks enables operators to engage with process modeling in a familiar and intuitive environment. The addition of guided training exercises further enhances learning by allowing staff to safely explore challenging scenarios, ultimately improving process understanding and operational readiness.
